Control Systems & Engineering Services

Across the history of modular syngas plant execution stretching to the late 1960's, weak in-house automation capabilities have limited many otherwise vertically-integrated firms.  In the PSA technology business, in particular, the absolute criticality of control systems engineering capabilities has been proven both to building excellent new plants, but even more importantly to providing comprehensive after sale service to owners.

Headwaters' in-house IC&E engineering capabilities facilitate not only the crucial automation technology of our PSA process, but also complement our full range of plants.  We delver everything from local visualization and control for individual compressor modules to complete automation systems for complex syngas plants.  Our automation engineering team is deeply integrated into our complete design and execution process, from the earliest stage of FEL through commissioning the plant, initial operations and ongoing customer support.

In addition to designing and building our own control systems, we provide controls engineering for legacy plants from other suppliers.  This facilitates ongoing operation when original OEM's have stepped away from service of existing assets.

Although we are capable in other automation environments, our preferred platform is Rockwell's Allen-Bradley family of PLC controllers, software and ancillaries.  This is the most widely accepted PLC automation platform in the process industry worldwide, and our in-house team benefits from Rockwell's extensive training and personnel development ecosystem in addition to years of practical experience.

For proprietary package units like PSAU's, a free-standing PLC controller is the industry standard.  This same PLC is usually powerful enough to control an entire reformer or syngas processing plant.  Usually, this PLC-controlled scope then communicates with the plant-wide DCS, Fire & Gas, and power distribution systems.  A variety of configurations and execution styles can be adopted to attain seamless integration of the Headwaters scope with a client's existing or planned facility.

In addition to our critical strength in controls engineering, Headwaters has strong abilities in process technology and engineering, metallurgy and corrosion engineering and detailed mechanical and electrical design.  Although for hydrogen plant and PSA projects, supply is normally vertically-integrated, we also participate as subcontractors for limited scope when dictated by client preferences.  We work with a variety of regional and international contractors to deliver civil engineering and construction services. 

Headwaters pilot plant and product development services are often in adjacent markets to hydrogen and synthesis gas, or to new companies who can benefit from our experience and know-how.  We have recently completed projects in markets as diverse as clean energy, personal care product manufacture, and hydrogen for both publicly-traded and privately-held clients.